Modular mobile robot

ABSTRACT

A modular mobile robot with a chassis including a power source housed therein. Right and left hand track modules are each removeably coupled to the robot chassis. Each track module includes a side plate, at least one drive wheel rotatable with respect to the side plate, a motor for driving the drive wheel, at least one idler rotatable with respect to the side plate, and a track extending around the drive wheel, the side plate, and the idler. A turret assembly with its own turret drive subsystem is removeably coupled to the robot chassis via a quick release mechanism.

RELATED APPLICATIONS

This application hereby claims the benefit of and priority to U.S. Provisional Application Ser. No. 61/007,681, filed on Dec. 14, 2007 under 35 U.S.C. §§119, 120, 363, 365, and 37 C.F.R. §1.55 and §1.78.

FIELD OF THE INVENTION

The subject invention relates to modular robots, typically remotely controlled mobile robots.

BACKGROUND OF THE INVENTION

Remotely controlled mobile robots are useful in a variety of applications and include military, police, fire, SWAT, and other users. Some robots have articulatable arms; others are equipped with weapons. Many have sensors, cameras, and the like. Some robots have wheels while others have tracks. In general, the robot chassis (or frame or body) is often ill-defined.

For example, U.S. Pat. No. 6,431,296 discloses a robotic platform with a main body including three tubes rigidly connecting the track side plates. The motors, drive pulleys, chains, and other mechanisms for driving the tracks are typically housed by the robot chassis or body. Other robots include complex drive subsystems, suspensions, and the like associated with the robot chassis and the track side plates. Components of the tracks cooperate with components of the robot chassis in a way that makes repair and replacement of the tracks, motors, and other components difficult. The design of the chassis and tracks are usually unique as between different robots and different manufacturers.

Robots with turrets and arms are also typically designed such that the turret and arm assemblies are unique in design for each robot chassis. In the assignee's “Talon” robot, for example, the arm assembly is not easily removable from the robot chassis. Robots with turrets also typically include a drive motor housed by the robot chassis. Therefore, it is typically not possible to easily remove the turret from such robots. A turret designed for one robot chassis cannot typically be used with another robot chassis.

Finally, in the design of small mobile robots, it is important that the chassis not be too wide or else the robot may become high centered when it traverses rocks and other obstacles. A narrower chassis is also preferred for robots which are designed to climb stairs and operate in close confines. Wider, more closely spaced tracks prevent the high centering problem but limit access to the chassis and the components and subsystem housed thereby, notably the batteries providing power for the robot drive and other subsystems.

The following co-pending patent applications by the applicant hereof are hereby incorporated herein by this reference: U.S. patent application Ser. Nos. 11/901,200 filed Sep. 13, 2007; 11/543,427 filed Oct. 5, 2006; 11/732,875 filed Apr. 5, 2007; 11/787,845 filed Apr. 18, 2007; 12/004,173 filed Dec. 19, 2007 and U.S. Provisional Patent Application Ser. No. 60/994,414 filed Sep. 19, 2007.

BRIEF SUMMARY OF THE INVENTION

It is therefore an object of this invention to provide a new robot with a more modular design.

It is a further object of this invention to provide such a robot which is preferably highly mobile and controlled remotely and wirelessly from an operator control unit.

It is a further object of this invention to provide such a robot which allows for repair, replacement, and refurbishment, possibly even in the field, of the primary robot components.

It is a further object of this invention to provide such a robot which includes, in one embodiment, fairly wide, fairly closely spaced tracks to reduce high centering and for maneuverability in close confines.

It is a further object of this invention to provide such a robot which, in one embodiment, includes track modules which can be spread outward with respect to the chassis to access the interior of the chassis.

It is a further object of this invention to provide such a robot which, in one embodiment, includes track modules which are self contained and easily decoupled from and coupled to the robot chassis.

It is a further object of this invention to provide such a robot which includes, in one embodiment, a turret which is also self contained and easily decoupled from and coupled to the robot chassis.

It is a further object of this invention to provide such a robot which, in one embodiment, is designed to accept different turret configurations, e.g., turrets carrying weapons and turrets with arms.

It is a further object of this invention to provide such a robot which includes, in one embodiment, a novel suspension subsystem.

It is a further object of this invention to provide such a robot which includes, in one embodiment, a novel track tensioning mechanism which allows the tracks to be quickly removed and replaced.

The subject invention results from the realization, in part, that a truly modular robot platform includes, in one example, a chassis housing the robot electronic and power subsystems, self contained track modules removeably coupled to the robot chassis, and a self contained turret assembly which is also removable from the robot chassis.

The subject invention, however, in other embodiments, need not achieve all these objectives and the claims hereof should not be limited to structures or methods capable of achieving these objectives.

The subject invention features a modular mobile robot chassis comprising a power source, and right and left hand track modules each removeably coupled to the robot chassis. Each track module includes a side plate, at least one drive wheel rotatable with respect to the side plate, a motor for driving the drive wheel, at least on idler rotatable with respect to the side plate, and a track extending around the drive wheel, the side plate, and the idler. A turret assembly includes its own turret drive subsystem and is removeably coupled to the robot chassis via a quick release mechanism.

In one example, both track module side plates are removeably coupled fore and aft to the robot chassis via couplings. The aft couplings may be hinges with removable hinge pins. Each hinge includes a pair of spaced ears coupled to the robot chassis, a sleeve coupled to the side plate and rotatably disposed between the ears, and a hinge pin extending between both ears and the sleeves. In one example, the fore couplings are clamp assemblies. Each clamp assembly includes a cam follower releasably urged against a portion of the robot chassis. Typically, the cam follower extends from a clamping bracket including a dowel pin spaced from the cam follower for receiving a shelf portion of the robot chassis. Each clamp assembly may further include a clamping bracket coupled to a track side plate and including a bore therethrough having a first longitudinal central axis. A cam throw sleeve is secured to the cam follower and includes a bore therethrough having a second longitudinal central axis offset from the first longitudinal access, and a handle for rotating the cam throw sleeve and the cam follower to engage the shelf portion of the robot chassis. In one preferred embodiment, each clamp assembly further includes a cam locking sleeve about the cam follower and within the cam throw sleeve. The cam locking sleeve includes a bore therethrough having a third longitudinal central axis adjustable with respect to the first and second longitudinal central axes to vary the clamping force of the clamp assembly. Typically, the cam locking sleeve includes a plurality of orifices therethrough corresponding in location to at least one orifice through the cam throw sleeve and a fastener through at least one orifice in the cam throw sleeve and a chosen orifice of the plurality of orifices in the cam locking sleeve to secure the cam locking sleeve with respect to the cam through sleeve.

The robot chassis may include at least one suspension device between a side plate and a coupling. One preferred suspension device includes a suspension cartridge comprising a base plate secured to the side plate including a pin and spaced damping pads and a pivot plate attached to the coupling and including an orifice which receives the pin of the base plate and a tang received between the spaced damping pads. Typically, there is a suspension cartridge between each coupling and its respective side plate.

Each track module may further include a tensioner for the idler. One preferred tensioner includes a tension block abutting a portion of the track module, a slide block for the idler, and a tension adjuster coupled to the slide block and extendable and retractable with respect to the tension block. The preferred tensioner further may include a plunger coupled on one end to the slide block and extending within and secured to the tension adjuster.

Typically, the turret includes a pintle extending therefrom, the robot chassis includes a pintle receiver, and the quick release mechanism includes a ball lock releasably securing the pintle in the pintle receiver. The robot chassis may include one or more electronic connectors and the turret includes one or more corresponding electronic connectors each electronically connected to a slip ring associated with the turret.

Each track may include cut-outs where the idlers engage the track to prevent debris from building up on the idler, or track. Each track module may further include a lubricious member guiding the track. Also, at least one kickstand is provided for raising the robot chassis to remove the tracks and/or track modules.

The subject invention also features a modular mobile robot comprising a robot chassis and left and right track modules removeably attached to the robot chassis. Each track module preferably includes at least one drive wheel, a motor for driving the drive wheel, at least one idler, and a track extending around the drive wheel, the side plate, and the idler.

Each track module may further include a tensioner for removing the track and adjusting the tension of the track. A turret assembly may be included and is removeably coupled to the robot chassis. In one preferred design, the robot chassis defines a battery cavity and the track modules are spreadable form the battery cavity via hinges attaching the track modules to the robot chassis to access the battery cavity. Clamp assemblies can be used to releasably lock the track modules in place on the robot chassis. Suspension modules between the track modules and the robot chassis are also typically included. The present design of a modular mobile robot in accordance with the subject invention features a robot chassis, self contained left and right track modules removeably attached to the robot chassis each including a tensioner for removing the track and adjusting the tension of the track and suspension modules between the track modules and the robot chassis, and a self contained turret assembly removeably coupled to the robot chassis.

One preferred robot chassis defines a battery cavity and the left and right track modules are spreadable with respect to the chassis via hinges attaching the track modules to the robot chassis to access the battery cavity. Clamp assemblies releasably lock the track modules in place on the robot chassis. In the present design, each track module includes a side plate, at least one drive wheel rotatable with respect to the side plate, a motor for driving the drive wheel, at least one idler rotatable with respect to the side plate, and a track extending around the drive wheel, the side plate, and the idler. When this design is employed, each hinge typically includes a pair of spaced ears coupled to the robot chassis, a sleeve coupled to the side plate and rotatably disposed between the ears, and a hinge pin extending through both ears and the sleeve. A clamp assembly for each track side plate releasably couples each track module to the robot chassis. One preferred clamp assembly includes a cam follower releasably urged against a portion of the robot chassis.

A new mobile robot in accordance with the subject invention includes a robot chassis defining a battery cavity; left and right track modules each including a side plate, at least one drive wheel rotatable with respect to the side plate, a motor for driving the drive wheel, at least one idler rotatable with respect to the side plate, and a track extending around the drive wheel, the side plate, and the idler; a hinge attaching each track module to the robot chassis; and a clamp assembly for each track module releasably coupling the track module to the robot chassis.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Other objects, features and advantages will occur to those skilled in the art from the following description of a preferred embodiment and the accompanying drawings, in which:

FIG. 1 is a schematic three-dimensional front view of an example of a modular robot in accordance with the subject invention;

FIG. 2 is a schematic three-dimensional exploded rear view of the modular robot shown in FIG. 1 depicting the primary modules associated with a robot in accordance with the subject invention;

FIG. 3 is a schematic three-dimensional exploded side view of the left hand track module of the robot shown in FIGS. 1-2;

FIG. 4 is a schematic three-dimensional front view showing a suspension cartridge for the robot shown in FIGS. 1-2 and also the rear hinge assembly of the left hand track module shown in FIG. 3;

FIG. 5 is a schematic three-dimensional exploded side view showing the primary components associated with the suspension cartridge and hinge assembly of FIG. 4;

FIG. 6 is a schematic three-dimensional exploded side view showing the primary components associated with a clamp subassembly for the forward portion of the track module shown in FIGS. 1-2;

FIG. 7 is a schematic cross-sectional side view of the clamp assembly shown in FIG. 6;

FIG. 8 is a schematic three-dimensional view of the throw cam sleeve component of the clamp subassembly shown in FIGS. 6-7;

FIG. 9 is a schematic cross-sectional front -view of the clamp assembly shown in FIG. 6;

FIG. 10 is a schematic three-dimensional front view of the chassis module of the robot shown in FIGS. 1-2;

FIG. 11 is a schematic three-dimensional front view of the clamp assembly shown in FIGS. 6-9 coupled to a suspension cartridge similar in design to the suspension cartridge shown in FIGS. 4-5;

FIG. 12 is a schematic three-dimensional front exploded view of the clamp assembly and suspension cartridge design of FIG. 11;

FIG. 13 is a schematic cross-sectional front view of a track tensioner mechanism for the robot shown in FIGS. 1-2;

FIG. 14 is a schematic three-dimensional exploded view showing the primary components associated with the tensioner assembly of FIG. 13;

FIG. 15 is a schematic three-dimensional front view of the robot shown in FIGS. 1-2 with the tracks spread apart in accordance with the subject invention;

FIG. 16 is a schematic three-dimensional front view of the robot shown in FIGS. 1-2 with the tracks thereof spread even further apart;

FIG. 17 is a schematic three-dimensional side view of another turret subassembly which can be used in connection with the robot chassis design shown in FIGS. 1-2; and

FIG. 18 is a schematic three-dimensional bottom view of a turret subassembly in accordance with the subject invention.

DETAILED DESCRIPTION OF THE INVENTION

Aside from the preferred embodiment or embodiments disclosed below, this invention is capable of other embodiments and of being practiced or being carried out in various ways. Thus, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. If only one embodiment is described herein, the claims hereof are not to be limited to that embodiment. Moreover, the claims hereof are not to be read restrictively unless there is clear and convincing evidence manifesting a certain exclusion, restriction, or disclaimer.

FIG. 1 shows an example of modular mobile robot 10 in accordance with the subject invention. Preferably, right hand and left hand track modules 12 a and 12 b are similarly configured and are removeably coupled to robot chassis 14, FIG. 2. The preferred track modules are fully self-contained (e.g., the only required electrical connection between the track modules and the chassis is a pair of cables providing power and feedback to the motors driving the tracks).

Turret 16, FIGS. 1 and 2 is similarly removable from chassis 14 preferably via a quick release mechanism such as a lockable ball lock. The turret is also typically fully self contained and includes, for example, its own motor for rotating the rotatable part of the turret. A few cables extend between the robot chassis and the turret to provide signals between the electronic subsystems housed by the robot chassis and the electronic subsystems of the turret (e.g., cameras, weapon electronics, arm motors, and the like). The particular turret shown in FIGS. 1 and 2 supports weapon 18 and is available from Precision Remotes, 1230 Brickyard Cove, #104, Point Richmond, Calif. 94801. But, other turrets, e.g., turrets carrying robot arms with end effectors and the like, can be used in connection with robot 10 chassis 14.

In this way, should track modules 12 a and 12 b and/or should turret 16 and/or chassis 14 become damaged, should different track modules or turrets be desired, or should repair, refurbishment, or replacement operations become necessary, the major subsystems associated with robot 10 are easily removable and replaceable due to the modular design of the primary robot components.

In this specific design shown in FIGS. 1-2, chassis 14 includes top plate 20 and body portion 22 housing a power source such as batteries 24 a and 24 b within cavity 26. The batteries are easily removed from chassis 14 for recharging or replacement as explained infra. Electronic subassemblies such as drive motor electronics, fire control electronics, microprocessor(s), transmitters, receivers, and the like are housed in electronic compartments 28 a and 28 b. Removal of turret 16 also allows easy access to these compartments for repair, maintenance, and refurbishment operations.

Connections 30 a, 30 b and 30 c allow electrical connections to be made from chassis 14 to turret 16 via similar connections associated therewith. From there, a slip ring associated with turret 16 allows electrical signals to proceed to and from the moveable portion of turret 16. A pintle associated with turret 16 is received in pintle receiver 32 located within receiver orifice 34 in chassis 14 top plate 20. A quick release mechanism releasably locks the turret pintle in the pintle receiver 32.

The Preferred Track Modules

Each track module in this particular embodiment includes, as shown for track module 12 b, FIG. 3, a side plate 40 b, drive wheel 42 b rotatable with respect to side plate 40 b, motor 44 b for driving drive wheel 42 b, and idlers 46 b and 48 b also both rotatable with respect to side plate 40 b. In FIGS. 1-2, corresponding reference numbers are used for the similarly configured track module 12 a. Motor 44 b, FIG. 3 is bolted to side plate 40 b and driven hub 50 b extends through orifice 52 b through side plate 40 b. Motor hub 50 b is coupled to the rotating drive wheel hub 54 b fastened to drive wheel 42 b. Flange 41 is a non-rotatable portion of drive motor 44 b and is fastened to side plate 40 b. Idlers 46 b and 48 b are coupled to bearing blocks 60 b and 62 b, respectively, each fastened to side plate 40 b.

Track 70 b extends around drive wheel 42 b, side plate 40 b and idlers 48 b and 46 b. Cogs 72 b of drive wheel 42 b engage drive lugs 74 b associated with tracks 70 b. Idlers 46 b and 48 b reside between adjacent lugs 74 b as shown in FIG. 2.

Cutouts or slots 76 b in track 70 b are positioned where drive wheel 42 b, and/or idlers 46 b and 48 b engage track 70 b to prevent debris from building up on the track, drive wheel, and the idlers, thereby minimizing detracking. Track guides 71 b are made of a lubricious material such as high density polyethylene.

Each track module 12 b, FIG. 3 also preferably includes tensioner assembly 80 b for adjusting the tension on track 70 b via moveable idler 46 b and for quickly removing and replacing tracks 70 b In this way, each track module is fully self contained and can be quickly removed from and assembled onto the robot chassis.

In the particular design shown in FIGS. 1-3, side plates 40 a and 40 b are removeably coupled fore and aft to robot chassis 14 via forward couplings 90 a and 90 b and rearward couplings 92 a and 92 b. Also, as shown more clearly in FIG. 3, there is a suspension cartridge associated with each coupling. Thus, suspension cartridge 94 b′ is associated with forward coupling 90 b and suspension cartridge 94 b″ is associated with aft coupling 92 b. The suspension cartridges are fastened to the track module side plates and the couplings are fastened to the suspension cartridges and (releasably) to the robot chassis.

The Preferred Rearward Coupling and Suspension Design

FIGS. 4-5 show aft coupling hinge assembly 92 b including hinge bracket 100 b with spaced ears 102 b. Hinge bracket 100 b is attached to the robot chassis at location 104, FIG. 2. Double pivot plate 106 b, FIGS. 4-5 includes sleeve 108 b rotatably disposed between ears 102 b via hinge pin 110 b extending through both ears 102 b and sleeve 108 b. Double pivot plate 106 b further includes tang 112 b pivotably disposed between spaced damping pads 114 b′ and 114 b″ of base plate 116 b. Pin 118 b equipped with rubber pivot sleeve 122 b extends through orifice 120 b in double pivot plate 106 b so pivot plate 106 b tang 112 b can rock between dampers 114 b′ and 114 b″. Cover plate 124 b completes suspension cartridge 94 b. The suspension cartridge thus allows for damped movement of the track module relative to the robot chassis.

Hinge bracket 100 b is attached to the robot chassis and suspension cartridge 94 b is attached to the track module via base plate 116′ in a way that provides a suspension for the track module (sleeve 108 b is coupled to the track module side plate via base plate 116 between damping pads 114 b′ and 114 b″). Quick release of the track module from the chassis is effected when hinge pin 110 b is removed.

The Preferred Forward Coupling and Suspension Module Design

The forward couplings 90 a and 90 b, FIGS. 1-2 are preferably clamp assemblies as shown in FIGS. 6-10 for clamp assembly 90 b. Cam follower 130 b releasably engages shelf portion 132 b, FIG. 10 of robot chassis 14 as also shown in FIG. 7. Rotating handle 134 b in one direction urges cam follower 130 b against the robot chassis shelf portion 132 locking it between cam follower 130 b and dowel pin 136 b of clamp bracket 138 b spaced from cam follower 130 b.

The preferred clamp bracket further includes cam throw sleeve 140 b and cam locking sleeve 142 b. Stem 144 b of cam follower 130 b is secured within cam locking sleeve 142 b itself secured within cam throw sleeve 140 b via bolt 166 b.

As shown more clearly in FIG. 9, the bore orifice in clamping bracket in 138 b which receives cam throw sleeve 140 b has a first longitudinal central axis x₁. The bore of cam throw sleeve 140 b (which receives cam locking sleeve 142 b) has a longitudinal central axis x₂ offset from central access x₁. The bore of cam locking sleeve 142 b (which receives cam follower 130 b stem 144 b) has still a different longitudinal central axis x₃.

FIG. 7 shows how cam throw sleeve 140 b has a thicker portion 160 b′ and a thinner portion 160 b″. Similarly, FIG. 7 shows how cam locking sleeve 142 has a thicker portion 162 b′ and a thinner portion 162 b″. By rotating cam locking sleeve 142 b within cam throw sleeve 140 b and fixing it in place therein via fastener 166 b through one of the several orifices 168 b through cam locking sleeve 142 b and orifice 170 b through cam throw sleeve 140 b, the position of the bore axis x₃ of locking sleeve 142 can be set with respect to the bore axis x₂ of cam throw sleeve 140 b to vary the clamping force of the clamping assembly.

The forward portion of the track modules are released from the robot chassis by turning handle 134 b whereupon cam follower 130 b is no longer urged tightly against the top portion of shelf 132 b, FIG. 10. Half-round cavity 180 b in the bottom of shelf portion 132 b receives dowel pin 136 b, FIGS. 6-7 when the track module is correctly positioned on the chassis. Further, detent 181 b, FIG. 6 with spring-loaded plunger 183 b, engages hole 185 b, FIG. 8, in cam throw sleeve 140 b to lock the clamp in the closed position.

FIGS. 11-12 further show how clamp bracket 138 b includes suspension mount 190 b coupled to a suspension cartridge 94 b′ similar in design to suspension cartridge 94 b, FIG. 5. Thus, similar reference numbers are used in FIGS. 11-12 for the suspension cartridge. Clamp 92 b via suspension mount 190 b is thus releasably coupled to the robot chassis and the track module via suspension cartridge 94 b′ coupled to the track module side plate via end plate 116 b′. Preferably, a similarly configured suspension cartridge is provided for each releasable coupling between the robot chassis and the track modules. Thus, in the preferred embodiment, the suspension cartridges are all similar as are the right hand and left hand track modules.

The Preferred Track Tensioner Assembly

One example of an idler tension assembly 80 b, FIGS. 2 and 3 is further described in reference to FIGS. 13-14. Tension block 200 b abuts a portion of track module side plate 40 b as shown in FIG. 3. Idler bearing cartridge 60 b is received in slide block 202 b, FIGS. 13-14. Tension adjuster 204 b is coupled to slide block 202 b via plunger 206 b and tension adjuster 204 b is extendable and retractable with respect to tension block 200 b by virtue of external threads on tension adjuster 204 b and corresponding internal threads inside tension block 200 b. Plunger 206 b is rotatably pinned to slide block 202 b via shoulder screw 208 b and is secured within tension adjuster 204 b via screw 210 b. Thus, the position of idler 46 b, FIG. 2 with respect to side plate 40 b can be varied.

Proper tension is provided via spring 212 b, FIGS. 13-14 about plunger 206 b and via the position of tension adjuster 204 b within tension block 200 b when nut feature 214 b is located close to indicator groove 216 b on plunger 206 b. To decrease the tension on the track for removal, nut feature 214 b on tension adjuster 204 b is turned clockwise a few turns into tension block 200 b. With the track tension reduced, tension block 200 b can be pulled manually toward slide block 202 b so that surface 201 b clears washers 203 b, FIG. 3. Now track tensioning cartridge 80 b is pivoted toward the chassis about shoulder screw 208 b and the slide block is released to slide toward the rear sufficiently to provide ample slack. In this way, a track can be quickly removed.

When a new track is then placed on track module, it is quickly tensioned by reversing the procedure above. That, with the tensioner cartridge 80 b still pivoted in towards the chassis, and the slide block 202 b located toward the rear, a track is placed over the wheels. To tension it, tension cartridge 80 b is swung toward side plate 40 b and surface 201 b is re-engaged between washers 203 b. Now, tension adjuster 204 b is turned counterclockwise to tension the track until indicator groove 216 b is adjacent to the front face nut feature 214 b.

The Design of the Preferred Spreadable Tracks

In one preferred embodiment, tracks 70 a and 70 b, FIGS. 1-2 are fairly wide and spaced fairly close together to limit the dead space under chassis 14 to prevent high centering and also to improve the maneuverability of the robot in close quarters. In one example, the tracks are 6 inches wide and spaced only 14 inches apart.

FIGS. 15-16 show how the track modules 12 a and 12 b can be spread apart to access the batteries within the chassis for recharging and the like. Kickstands 230 a and 230 b are shown pivoted from their stored position and engaged with the ground to raise the front of the robot using handles 232 a and 232 b.

Clamp handles 134 a and 134 b (see FIGS. 6-7) are rotated to disengage the fore clamp assemblies locking the track modules 12 a and 12 b to the robot chassis. Track modules 12 a and 12 b can now be spread eight inches apart as shown in FIG. 15 or even as much as 71 inches apart as shown in FIG. 16 (by virtue of aft hinge assemblies 92 a and 92 b, FIGS. 2-5) to access and charge or replace batteries 24 a and 24 b, to repair or replace any components associated with the track modules including the motors, tracks, tensioner assemblies, idlers and the like. By removing the aft coupling hinge pins (e.g., hinge pin 110 b, FIGS. 4-5), the track modules can be completely removed from the robot chassis for repair or replacement and/or to access the subassemblies housed or associated with the robot chassis.

The Preferred Turret Design

In a similar fashion, turret 16, FIGS. 1-2 can be quickly removed from the robot chassis 14 to access any subassemblies associated with chassis 14, to repair or replace the turret, and/or to reconfigure the robot with a different style turret. FIG. 17 shows turret 16′ pivotably attached to robot chassis top plate 20 and arm subassembly 318. Turret 16′ is rotatably driven with respect to robot chassis 12 via motors 370 a and 370 b. Advantageously, as many of the electronics, cameras, and the like as possible are housed on or by turret 16′ rendering it fully self contained. Also, the operation of robot lower arm subassembly 318 does not interfere with other robot components. Such a design also allows the turret and arms subassemblies to be used with different robot chassis configurations.

Lower arm 318 is shown in its stored position within storage channel member 378. Also shown in FIG. 17 is motor controller 360 b, gear box 380 b, and clutch 362 b for the upper arm (not shown) and gearbox 380 a and clutch 362 a for lower arm subassembly 318. Motor controller 360 b drives lower arm 318 up and down via gear box 380 b and clutch 362 b. Another motor/controller combination on the other side of arm 318 drives gear box 380 a turning a chain within lower arm 318 in order to pivot the upper arm (not shown) within respect to the lower arm. Turret drive motors 370 a and 370 b each drive a gear which engages a fixed in place turret drive gear to rotate the turret. Additional details concerning such a robot arm turret subassembly are disclosed in a co-pending U.S. Patent Application entitled “Mobile Robot” incorporated herein by this reference. Other turret designs are possible. Typically, the turret features its own drive subsystem.

FIG. 18 shows turret pintle 400 extending outward from the bottom of the non-rotatable portion 402 of turret 16″. Pintle 400 is releasably fitted in receptacle 32, FIG. 2 via a quick release mechanism such as a ball lock 401. Electrical connectors 30 a′, 30 b′, and 30 c′ associated with non-moveable turret portion 402 corresponds to electrical connectors 30 a, 30 b, and 30 c, FIG. 2 associated with robot chassis 14. A slip ring within 30 c′ and any electronic subassemblies associated with turret 16″ (e.g., the turret drive motors, cameras, processors, fire control subsystems, arm drive motors, and the like).

Thus, turret 16″, whether it includes arm subassemblies, weapons, or the like, is fully self contained and is easily removed from and coupled to the robot chassis via the quick release lock mechanism and the cables interconnecting connectors 30 a′, 30 b′, and 30 c′ and connectors 30 a, 30 b, and 30 c, FIG. 2.

The result in the preferred and other embodiments is a new robot with a more modular design. Repair, replacement, and refurbishment of the primary robot components may be possible even in the field (and/or at repair depots, for example). The fairly wide, fairly closely spaced tracks prevent high centering and improved maneuverability in close confines. By spreading the tracks outward with respect to the chassis, access to the interior of the chassis is possible. The novel suspension subsystem and the novel track tensioning mechanism also allow the tracks to be quickly removed and replaced. The preferred track modules are self contained and thus easily decoupled from and attachable to the robot chassis. The preferred turret is also self contained and easily coupled to and decoupled from the robot chassis.

Although specific features of the invention are shown in some drawings and not in others, this is for convenience only as each feature may be combined with any or all of the other features in accordance with the invention. For example, other track modules, suspension subsystems, couplings, tensioners, and turrets are within the scope of the subject invention. The words “including”, “comprising”, “having”, and “with” as used herein are to be interpreted broadly and comprehensively and are not limited to any physical interconnection. Moreover, any embodiments disclosed in the subject application are not to be taken as the only possible embodiments.

In addition, any amendment presented during the prosecution of the patent application for this patent is not a disclaimer of any claim element presented in the application as filed: those skilled in the art cannot reasonably be expected to draft a claim that would literally encompass all possible equivalents, many equivalents will be unforeseeable at the time of the amendment and are beyond a fair interpretation of what is to be surrendered (if anything), the rationale underlying the amendment may bear no more than a tangential relation to many equivalents, and/or there are many other reasons the applicant can not be expected to describe certain insubstantial substitutes for any claim element amended.

Other embodiments will occur to those skilled in the art and are within the following claims. 

1. A modular mobile robot comprising: a robot chassis; a power source housed therein; right and left hand track modules each removably coupled to the robot chassis, each track module including: a side plate, at least one drive wheel rotatable with respect to the side plate, a motor for driving the drive wheel, at least one idler rotatable with respect to the side plate, and a track extending around the drive wheel, the side plate, and the idler; and a turret assembly with its own turret drive subsystem and removeably coupled to the robot chassis via a quick release mechanism.
 2. The robot of claim 1 in which both track module side plates are removeably coupled fore and aft to the robot chassis via couplings.
 3. The robot of claim 2 in which the aft couplings are hinges with removable hinge pins.
 4. The robot of claim 3 in which each hinge includes a pair of spaced ears coupled to the robot chassis, a sleeve coupled to the side plate and rotatably disposed between the ears, and a hinge pin extending between both ears and the sleeve.
 5. The robot of claim 2 in which the fore couplings are clamp assemblies.
 6. The robot of claim 5 in which each clamp assembly includes a cam follower releasably urged against a portion of the robot chassis.
 7. The robot of claim 6 in which the cam follower extends from a clamping bracket including a dowel pin spaced from the cam follower for receiving a shelf portion of the robot chassis.
 8. The robot of claim 6 in which each clamp assembly further includes a clamping bracket coupled to a track side plate and including a bore therethrough having a first longitudinal central axis, a cam throw sleeve secured to the cam follower and including a bore therethrough having a second longitudinal central axis offset from the first longitudinal access, and a handle for rotating the cam throw sleeve and the cam follower to engage the shelf portion of the robot chassis.
 9. The robot of claim 8 in which each clamp assembly further includes a cam locking sleeve about the cam follower and within the cam throw sleeve, the cam locking sleeve including a bore therethrough having a third longitudinal central axis adjustable with respect to the first and second longitudinal central axes to vary the clamping force of the clamp assembly.
 10. The robot of claim 9 in which the cam locking sleeve includes a plurality of orifices therethrough corresponding in location to at least one orifice through the cam throw sleeve and a fastener through at least one orifice in the cam throw sleeve and a chosen orifice of the plurality of orifices in the cam locking sleeve to secure the cam locking sleeve with respect to the cam throw sleeve.
 11. The robot of claim 2 further including at least one suspension device between a side plate and a coupling.
 12. The robot of claim 11 in which the suspension device includes a suspension cartridge comprising: a base plate secured to the side plate including a pin and spaced damping pads, and a pivot plate attached to the coupling and including an orifice which receives the pin of the base plate and a tang received between the spaced damping pads.
 13. The robot of claim 12 in which there is a suspension cartridge between each coupling and its respective side plate.
 14. The robot of claim 1 in which each track module further includes a tensioner for the idler.
 15. The robot of claim 14 in which each tensioner includes: a tension block abutting a portion of the track module, a slide block for the idler, and a tension adjuster coupled to the slide block and extendable and retractable with respect to the tension block.
 16. The robot of claim 15 in which each tensioner further includes a plunger coupled on one end to the slide block and extending within and secured to the tension adjuster.
 17. The robot of claim 1 in which the turret includes a pintle extending therefrom, the robot chassis includes a pintle receiver for the pintle, and the quick release mechanism includes a ball lock releasably securing the pintle in the pintle receiver.
 18. The robot of claim 1 in which the robot chassis includes one or more electronic connectors and the turret includes one or more corresponding electronic connectors each electrically connected to a slip ring associated with the turret.
 19. The robot of claim 1 in which each track includes cut-outs where the idlers engage the track to prevent debris from building up on the idler, or track.
 20. The robot of claim 1 in which each track module further includes a lubricious member guiding the track.
 21. The robot of claim 1 further including at least one kickstand for raising the robot chassis to remove the tracks and/or track modules.
 22. A modular mobile robot comprising: a robot chassis; and left and right track modules removeably attached to the robot chassis, each track module including: at least one drive wheel, a motor for driving the drive wheel, at least one idler, and a track extending around the drive wheel, the side plate, and the idler.
 23. The robot of claim 22 in which each track module further includes a tensioner for removing the track and adjusting the tension of the track.
 24. The robot of claim 22 further including a turret assembly removeably coupled to the robot chassis.
 25. The robot of claim 22 in which the robot chassis defines a battery cavity and the track modules are spreadable from the battery cavity via hinges attaching the track modules to the robot chassis to access the battery cavity.
 26. The robot of claim 25 further including clamp assemblies for releasably locking the track modules in place on the robot chassis.
 27. The robot of claim 25 further including suspension modules between the track modules and the robot chassis.
 28. The robot of claim 25 in which each track includes cut-outs where the idlers engage the track to prevent debris from building up on the idler or track.
 29. The robot of claim 25 in which each track module further includes a lubricious member guiding the tracks.
 30. A modular mobile robot including: a robot chassis; self contained left and right track modules removably attached to the robot chassis each including a tensioner for removing the track and adjusting the tension of the track and suspension modules between the track modules and the robot chassis; and a self contained turret assembly removeably coupled to the robot chassis.
 31. A mobile robot comprising: a robot chassis defining a battery cavity; and left and right track modules spreadable with respect to the chassis via hinges attaching the track modules to the robot chassis to access the battery cavity.
 32. The mobile robot of claim 31 further including clamp assemblies for releasably locking the track modules in place on the robot chassis.
 33. The robot of claim 31 in which each track module includes: a side plate, at least one drive wheel rotatable with respect to the side plate, a motor for driving the drive wheel, at least one idler rotatable with respect to the side plate, and a track extending around the drive wheel, the side plate, and the idler.
 34. The robot of claim 33 in which each hinge includes a pair of spaced ears coupled to the robot chassis, a sleeve coupled to the side plate and rotatably disposed between the ears, and a hinge pin extending through both ears and the sleeve.
 35. The robot of claim 33 further including a clamp assembly for each track side plate releasably coupling each track module to the robot chassis.
 36. The robot of claim 35 in which each clamp assembly includes a cam follower releasably urged against a portion of the robot chassis.
 37. The robot of claim 36 in which the cam follower extends from a clamping bracket including a dowel pin spaced from the cam follower for receiving a shelf portion of the robot chassis.
 38. The robot of claim 36 in which each clamp assembly further includes a clamping bracket coupled to a track side plate and including a bore therethrough having a first longitudinal central axis, a cam throw sleeve secured to the cam follower and having a bore with a second longitudinal central axis offset from the first longitudinal axis, and a handle for rotating the cam throw sleeve and the cam follower.
 39. The robot of claim 38 in which each clamp assembly further includes a cam locking sleeve about the cam follower and within the cam throw sleeve, the cam locking sleeve including a bore having a third longitudinal central axis adjustable with respect to the first and second longitudinal central axes to vary the clamping force of the clamp assembly.
 40. The robot of claim 39 in which the cam locking sleeve includes a plurality of orifices therethrough corresponding in location to at least one orifice through the cam throw sleeve and a fastener extending through the at least one orifice in the cam throw sleeve and a chosen orifice of the plurality of orifices in the cam locking sleeve to secure the cam locking sleeve with respect to the cam throw sleeve.
 41. A mobile robot comprising: a robot chassis defining a battery cavity; and left and right track modules spreadable from the battery cavity via aft hinges attaching the track modules to the robot chassis and fore clamp assemblies releasably locking the track modules in place on the robot chassis to access the battery cavity when the right and left track modules are spread apart.
 42. A mobile robot comprising: a robot chassis defining a battery cavity; left and right track modules each including a side plate, at least one drive wheel rotatable with respect to the side plate, a motor for driving the drive wheel, at least one idler rotatable with respect to the side plate, and a track extending around the drive wheel, the side plate, and the idler; a hinge attaching each track module to the robot chassis; and a clamp assembly for each track module releasably coupling the track module to the robot chassis.
 43. The robot of claim 42 in which each clamp assembly includes a cam follower releasably urged against a portion of the robot chassis.
 44. The robot of claim 12 in which the cam follower extends from a clamping bracket including a dowel pin spaced from the cam follower for receiving a shelf portion of the robot chassis.
 45. The robot of claim 42 in which each clamp assembly further includes a clamping bracket coupled to a track side plate and including a bore therethrough having a first longitudinal central axis, a cam throw sleeve secured to the cam follower and including a bore having a second longitudinal central axis offset from the first longitudinal axis, and a handle for rotating the cam throw sleeve and the cam follower.
 46. The robot of claim 45 in which each clamp assembly further includes a cam locking sleeve about the cam follower and within the cam throw sleeve, the cam locking sleeve including a bore with a third longitudinal central axis adjustable with respect to the first and second longitudinal central axes to vary the clamping force of the clamp assembly.
 47. The robot of claim 46 in which the cam locking sleeve includes a plurality of orifices therethrough corresponding in location to at least one orifice in the cam throw sleeve and a fastener extends through the at least one orifice in the cam throw sleeve and a chosen orifice of the plurality of orifices in the cam locking sleeve to secure the cam locking sleeve with respect to the cam throw sleeve. 